NC0004618_Inspection_20130807

NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Water Quality Programs
Pat McMrory Thomas A. Reeder John E. Skvarla, III
Governor Director Secretary
August 7, 2013
Mark Cabral
Alamac American Knits LLC
P.O. Box 1347
Lumberton, NC.28359
SUBJECT: July 24, 2013 Compliance Evaluation Inspection
Alamac American Knits LLC
Alamac American Knit / Lumberton
Permit No: NC0004618
Robeson County
Dear Mr. Cabral:
Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted
on July 24, 2013. The Compliance Evaluation Inspection was conducted by Mark Brantley,
Environmental Senior Specialist, of the Fayetteville Regional Office. The facility was found to be in
Compliance with permit NC0004618. The cooperation of Mr.. Cleve Collins, Grade IV ORC, was greatly
appreciated. As a reminder, preservation of the Waters of the State can only be achieved through
consistent NPDES Permit compliance.
Comments
• Facility was clean and neat in appearance at the time of the inspection. Mr. Collins and his staff
do a great job at maintaining this facility.
• Log books, maintenance records and log books appear to be well kept and up to date.
• No transcription errors were found in the monthly discharge report for March 2013 when it was
compared to laboratory bench sheets.
Location: 225 Green Street, Suite 714, Fayetteville, NC 28301
Phone [phone]\FAX: [phone]\Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper

Mr. Cabral
Page 2
August 7, 2013
Please refer to the enclosed inspection report for additional observations and comments. If you or your
staff have any questions, please call me at 910-433-3327.
Sincerely,
Mark Brantley
Environmental Senior Specialist
Surface Water Protection Section
Fayetteville Regional Office
cc: Cleveland L Collins, ORC
Central Files
'" ayetteville.:Files

United States Environmental Protection Agency
PA Washington, D.C. 20460
Water Compliance InSpPf tinn'Repnrt
FE
OMB Ap2d40..
OMB No.2040 0057
Approval expires 8 31 98
Section A: National Data,System'Coding'(Le PCS)
Transaction Code NPDES yr/mo/day Inspection
1 INI 2 15 I 31 NC0004618 111 121 13/07/24 117
Type Inspector Fac Type
18I C I . 19 LS I; 2911
I I I I I 1 1 I I`I I I I'I I I66
•
Remarks" _
211 I I I I I I I I I I I I I I I I I I I I I I I I I I I I li
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 , QA ---- --------------Reserved---------------
67I 169 701 31 71 I N I 72I N I 73I I 174 751 1 1 1 1 1 1 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Alamac American Knit / Lumberton
1885 Alamac Rd
Lumberton NC 28358
Entry Time/Date
09:20 AM 13/07/24
Permit Effective Date
09/10/01
Exit Time/Date
11:30 AM 13/07/24
Permit Expiration Date
14/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Cleveland L Collins/ORC/910-618-2456/ -
Other Facility Data
.
Name, Address of Responsible OfficiallTitle/Phone and Fax Number
Contacted
Mark Cabral,PO Box 1347 Lumberton NC 28359//910-618-2235/9106182292 No
Section C: Areas Evaluated During Inspection (Check only{hose areas evaluated)
Permit ■ Flow Measurement • Operations & Maintenance Records/Reports
Self -Monitoring Program Facility Site Review • Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Mark Brantley FRO WQ//910-433-3300 Ext.727/
•
Akin 4g - 7- i3
Signature of Management Q A Reviewer - Agency/Office/Phone and Fax Numbers Date Belinda S Henson FRO WQ//910-433-3300 Ext.726/ 8"8" -!/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page.#

NPDES yr/mo/day Inspection Type
31 NC0004618 111 121 13/07/24 117 181 CI
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Comments
Facility was clean and neat in appearance at the time of the inspection. Mr. Collins and his staff do a great
job at maintaining this facility.
Log books, maintenance records and log books appear to be well kept and up to date.
No transcription errors were found in the monthly discharge report for March 2013 when it was compared to
laboratory bench sheets.
Page # 2

Permit: NC0004618 Owner - Facility: Alamac American Knit /. Lumberton.
Inspection Date: 07/24/2013 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ n n n
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids,•pH, DO, Sludge ■ n n n
Judge, and other that are applicable?
Comment:
Permit
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment:
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit?
Is all required information readily available, complete and current?
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results consistent with data reported on DMRs?
Is the chain -of -custody complete?
Dates, times and location of sampling
Name of individual performing the sampling
Results of analysis and calibration
Dates of analysis -
Name of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters?
Has the facility submitted its annual compliance report to, users and DWQ?
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification?
Is the backup operator certified at one grade less or greater than the facility classification?
Is a copy of the current NPDES permit available on site?
Yes No NA NE
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Page # 3

Permit: NC0004618 Owner - Facility: Alamac American Knit / Lumberton
Inspection Date: 07/24/2013 Inspection Type: Compliance Evaluation
Record Keeping
Facility has copy of previous year's Annual Report on file for review?
Comment:
Flow Measurement - Effluent
# Is flow meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
Comment:
Pump Station - Effluent
Is the pump wet well free of bypass lines or structures?
Are all pumps present?
Are all pumps operable?
Are float controls operable?
Is SCADA telemetry available and operational?
Is audible and visual alarm available and operational?
Comment:
Secondary Clarifier
Is the clarifier free of black and odorous wastewater?
Is the site free of excessive buildup of solids in center well of circular clarifier?
Are weirs level?
Is the site free of weir blockage?
Is the site free of evidence of short-circuiting?
Is scum removal adequate?
Is the site free of excessive floating sludge?
Is the drive unit operational?
Is the return rate acceptable (low turbulence)?
Is the overflow clear of excessive solids/pin floc?
Is the sludge blanket level acceptable? (Approximately'/< of the sidewall depth)
Comment:
Aeration Basins
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
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Yes No NA NE
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Yes No NA NE
Page # 4

Permit: NC0004618
Owner - Facility: Alamac American Knit / Lumberton
Inspection Date: 07/24/2013 Inspection Type: Compliance Evaluation
Aeration Basins Yes No,, NA NE
Mode of operation Ext. Air
Type of aeration system Surface,
Is the basin free of dead spots? ■ n n n
Are surface aerators and mixers operational? ■ n ,n n
Are the diffusers operational? n n ■ n
Is the foam the proper color for the treatment process? ■ n n n
Does the foam cover less than 25% of the basin's surface? • n n n
Is the DO level acceptable? - ■ n n n
Is the DO level acceptable?(1.0 to 3.0 mg/I) • n n n
Comment:
Pumps-RAS-WAS Yes No NA NE
Are pumps in place? ■ n n n
Are pumps operational? Al n n n
Are there adequate spare parts and supplies on site? n ❑ n ■
Comment:
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? ■ n n n
Are all other parameters(excluding field parameters) performed by a certified lab? ■ n n n
# Is the facility using a contract lab? ■ n n n
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? • n n n
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? n n ■ n
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ■ n n n
Comment:
Influent Sampling Yes No NA NE
# Is composite sampling flow proportional? n n ■ n
Is sample collectedabove side streams? ■ n n n
Is proper volume collected? • n n n
Is the tubing clean? r ■ n n n
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n n
Is sampling performed according to the permit? • n n n
Page # 5

Permit: NC0004618 Owner - Facility: Alamac American Knit / Lumberton
Inspection Date: 07/24/2013 Inspection Type: Compliance Evaluation
Influent Sampling Yes No NA NE
Comment:
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment:
Upstream / Downstream Sampling
Yes No NA NE
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Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ ❑ 0 0
Comment:
Page # 6

Regional Inspectors' Checklist for Field Parameters
Facility Name: Alamac Knits
Regional Plant Inspector: Mark Brantley
NPDES #: NC0004618
Regional Inspector Contact #: 910-433-3327
Field Lab Certification #: 144
Region: Fayetteville
Lab Contact: Cleve Collins
Date: July 24, 2013
I. Check the parameter(s) performed at this site for reporting purposes.
❑ Total Residual Chlorine (TRC) ® Temperature (TEMP) ® Specific Conductivity (SC)
pH ®.Dissolved Oxygen (DO) ❑ Settleable Residue (SETT)
II. General Laboratory (note any exceptions in section XI
Are instruments, meters, probes, photometric cells, etc. maintained in good condition?
A
Yes ❑ No
Are standards, reagents and consumables used within manufacturer expiration dates?
[TRC gel standard is exempt.]
Yes ❑ No
r4refhetfdiiowingems docuinentedF(,
rhe* applicable }� ,,_
,,. 7t
'_�
_ Y _
item __ r r
TG e`H a.,y.
TEIIIIP
D©
S
�rt`►ET` . .
Date of sample collection*
Time of sample collection*
4
4
4
4
Sample collector's initials or signature
\I
4
4 __
4
Date of sample analysis*
4
4
4
4
Time of sample analysis*
q
4
4
4
Analyst initials or signature
4
4
4
4
Sample location
q
4
4
4
*Date and time of sample collection and analysis may be the same for in situ or on -site measurements.
. 7atal.Residual- Moil i e , .,. _ . 7
z t:5
=
Total Residual Chlorine meter make and model:
Is a check standard analyzed each day of use? (Circle one: gel or liquid standard)
Yes No
What is .the assigned/observed value of the daily check standard?
Is a 5-point calibration verification performed? Note date of last verification:
Yes No
Yes No
-
Alternatively, does the lab construct a linear regression, using 5 standards, to calculate
results? Note date of last calibration curve constructed:
True values: ❑ pg/L ❑ mg/L
,
Obtained values: ❑ pg/L ❑ mg/L
What program are samples analyzed on?
Yes No
Are results reported in proper units? Check one: ❑ pg/L ❑ mg/L
Are results reported between the facility's permit limit and the compliance limit of 50 pg/L?
If value is Tess than the low standard, report as "<x", where x=low standard conc.
Yes No
Are samples analyzed within 15 minutes of collection?
Yes No
2I ` '. ' ■ _".r 1 u h ^5 y i, 3{ ._ �..._ -
pH meter make and model:
Accumet Model
10 pH meter
Is the pH meter calibrated with at least 2 buffers per mfg's instructions each day of use?
Note buffers used:
Yes ❑ No
Is the pH meter calibration checked with an additional buffer each day of use? Note check
buffer used:
Yes ❑ No
Does the check buffer read within ±0.1 S.U. of the known value?
/1 Yes ❑ No
Are the following items documented:•
Meter calibration?
►1 Yes ❑ No
Check buffer reading?
,I Yes ❑ No
Are samples analyzed within 15 minutes of collection?
Yes ❑ No
Are sample results reported to 0.1 pH units?
1 Yes ❑ No

V :Temperature - s
What instrument(s) is used to measure temperature? Check all that apply:❑ pH meter
YSI 54A
a DO meter ❑ Conductivity meter ❑ Digital thermometer ❑ Glass thermometer
Is the instrument/thermometer calibration checked at least annually against a NIST
traceable or NIST certified thermometer?
_
Yes ❑ No
Are temperature corrections (even if zero) posted on the instrument/thermometer?
/1 Yes ❑ No
Are samples measured in situ or on -site? [REQUIRED - there is no holding time for
temperature]
►1
Yes ❑ No
Are sample results reported in degrees C?
Yes ❑ No
'
11i_ Dissolved OxY9en _ _ - .--- - '_.. .... x ... . _. .. ,..... --{.
DO meter make and model:
YSI 54A
Is the air calibration of the DO meter performed each day of use?
I Yes ❑ No
Are the following items documented:
Meter calibration?
r
Yes ❑ No
Are samples analyzed within 15 minutes of collection?
/1
Yes ❑ No
Are results reported in mg/L?
►1
Yes ❑ No
a/11 Oonduc#14ty _ , ^ _
Conductivity meter make and model:
Orion Model 160
Is the meter calibrated daily according to the manufacturer's instructions? Note standard
used (this is generally a one -point calibration):
4
Yes ❑ No
Is a daily check standard analyzed? Note value:
/1 Yes ❑ No
Are the following items documented:
Meter calibration?
/1 Yes ❑ No
Are samples analyzed within 28 days of collection?
/1 Yes ❑ No
Are results reported in pmhos/cm (some meters display equivalent pS/cm units)?
A Yes ❑ No
1:V111 } , r Settleable, Residue t - t �-_ : =
,
Does the laboratory have an Imhoff Cone in good condition?
Yes No
Yes No
Is the sample settled for 1 hour?
Is the sample agitated after 45 minutes?
Yes No
Are the followingitems documented:
Volume of sample analyzed? Note volume analyzed:
Yes No
Date and time of sample analysis (settling start time)? •
Yes No
Yes No
Yes No
Yes No
Yes No
Time of agitation after 45 minutes of settling?
Sample analysis completion (settling end time)?
Are samples analyzed within 48 hours of collection?
Are results reported in ml/L?
I- _ t Was a paperYtra l (compari g contractilab-and on- ite data to
2-- ipe formed? Ifso hst monthsreviewad. March; 201 � - _
X: u" is follow up`by the.Laboratory Certification program reco timended?
Yes~ 61 _No
XI. Additional comments:
Please submit a copy of this completed form to the Laboratory Certification program at:
DWQ Lab Certification, Chemistry Lab, Courier # 52-01-01
Electronic copies may be emailed to linda.chavisncdenr.qov.
Revision 04/20/2012